US4316928A - Mechanically surface finished textile material - Google Patents
Mechanically surface finished textile material Download PDFInfo
- Publication number
- US4316928A US4316928A US06/092,815 US9281579A US4316928A US 4316928 A US4316928 A US 4316928A US 9281579 A US9281579 A US 9281579A US 4316928 A US4316928 A US 4316928A
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- Prior art keywords
- fabric
- fibers
- sample
- fabrics
- sanding
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Classifications
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C11/00—Teasing, napping or otherwise roughening or raising pile of textile fabrics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
- B24B19/22—Single-purpose machines or devices for particular grinding operations not covered by any other main group characterised by a special design with respect to properties of the material of non-metallic articles to be ground
- B24B19/223—Single-purpose machines or devices for particular grinding operations not covered by any other main group characterised by a special design with respect to properties of the material of non-metallic articles to be ground of paper or similar sheet material, e.g. perforating, cutting by means of a grinding wheel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
- B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C23/00—Making patterns or designs on fabrics
- D06C23/02—Making patterns or designs on fabrics by singeing, teasing, shearing, etching or brushing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
- B29C2059/027—Grinding; Polishing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2973—Particular cross section
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2973—Particular cross section
- Y10T428/2978—Surface characteristic
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31—Surface property or characteristic of web, sheet or block
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3065—Including strand which is of specific structural definition
- Y10T442/3089—Cross-sectional configuration of strand material is specified
- Y10T442/3114—Cross-sectional configuration of the strand material is other than circular
Definitions
- the present invention relates to a process and apparatus for surface finishing fabrics by mechanical means to provide a fabric product having improved surface softness and a desirable fabric hand.
- the present invention also relates to a textile fabric with modified surface which may be made by the process.
- fabrics may be mechanically face-finished to provide various effects on the fabric, such as a soft surface feel, to generate cover, or even to give fabrics made from filament yarns a spun-like hand.
- mechanical face-finishing techniques include napping and sanding techniques, the particular technique employed as well as operating parameters selected being determined by the desired effect as well as by the nature of the fabric to be finished.
- Sanding of textile fabrics also variously referred to in the art as buffing or emerizing, is generally accomplished according to known methods by passing the fabric over rapidly-rotating cylinders covered with an abrasive, e.g., sanding paper of a suitable degree of fineness or coarseness.
- the sanding grains which come into contact with the fabric surface for a period of time, depending upon operating conditions, abrade the surface fibers of the fabric and raise a cover which is generally shorter than that which is obtainable by napping.
- the textile fabric may be forced onto the abrading surface by either tensioning or by setting a predetermined gap somewhat less than the fabric thickness between the abrading surface and a backing device. Frequently the fabric surface obtained by such mechanical finishing techniques must be sheared after sanding or other treatment to provide a product having the desired uniformity of the nap or pile height.
- the process of the present invention has been developed to provide a more uniform surface finish to fabrics than conventional methods, even on fabrics with tight warp ends; streaking has been minimized or prevented entirely.
- the process can be easily controlled and finish characteristics can be adjusted predictably by varying operating parameters.
- the surface finish obtained, depending on operating conditions and the fabric substrate may have few broken fibers although it may be characterized as having a very soft touch, or, if desired, may have a dense but very short cover.
- the surface hand of the treated fabric may be suede-like, cotton-like or it may even have the desirable feel characteristics of wool.
- the fabric itself may be caused to develop more drape, or, if desired, processing parameters may be adjusted so as to change primarily only the fabric finish, e.g., surface feel, with little or no effect on the fabric drape and crispness.
- processing parameters may be adjusted so as to change primarily only the fabric finish, e.g., surface feel, with little or no effect on the fabric drape and crispness.
- Synthetic filament fabrics such as polyester filament fabrics, processed according to the present invention may acquire many of the desired hand and appearance characteristics of spun fabrics and frequently also may acquire a desirable surface feel normally associated with fabrics made from finer denier fibers.
- Fabrics processed according to the present invention may possess enhanced adhesion characteristics, that is, they can be caused to adhere better than untreated materials to another material, such as for instance polyurethane sheet material, using a suitable adhesive.
- the present invention relates to a process for mechanically surface finishing a textile fabric, which comprises continuously feeding said fabric from a source of supply such that, said fabric lies in a single plane, subjecting successive adjacent sections of the fabric to intermittent mechanical impact with an abrasive means across the width of said fabric thereby avoiding substantial sustained contact between said fabric and said abrasive means, said mechanical impact being at a force and frequency sufficient to cause a substantially uniform modification of the surface characteristics of said fabric.
- the present invention also relates to a textile material which may be made according to the process of the invention having a body portion containing a plurality of fibers, of which at least 20 percent by weight, and preferably at least 45 percent by weight, are synthetic fibers, e.g., thermoplastic synthetic fibers such as polyester or nylon fibers.
- the remaining portion of the textile material if it is not totally synthetic, may be made up of natural fibers and may even include some nonfibrous materials.
- the fibers in the textile material have a curvature and are arranged so as to have convex side portions and concave side portions.
- Those convex side portions of the fibers of the material which are exposed are substantially scarred and they contain a multiplicity of generally short, rather thick lamella-shaped protrusions extending therefrom. While the actual length and number of these protrusions may vary considerably according to the invention depending upon the type of material treated and the severity of treatment, on the average it has been determined that the length of such protrusions will in general be quite short, e.g., less than about 0.05 mm., preferably less than about 0.03 mm. from the base of the protrusions where they are joined to the main body portion of the fiber to the tip of the protrusions.
- the shape of the protrusions has been described in general as being lamella-shaped. This characterization is not meant to imply that individual protrusions have a precisely identifiable and reproducible shape. Rather, the term “lamella” is used in its conventional sense to refer to a thin, flat scale or part (see Webster's Seventh New Collegiate Dictionary, 1965 ed.). Individual protrusions, furthermore, may be of a rather irregular shape, some even being rather long by comparison to their cross-sectional dimension. Nonetheless, on the average, the protrusions are rather short and are rather flat in cross-sectional dimension rather than being of a generally circular cross-sectional dimension which might characterize a true "fibril.”
- individual synthetic fibers at or near the surface of the textile material may actually be flattened somewhat as a result of the mechanical surface finishing.
- the cross-sectional dimension of the individual fibers is substantially circular prior to mechanical surface treatment, it may be observed that after mechanical surface finishing the cross-sectional dimension becomes somewhat ovoid. If the cross-sectional dimension is multi-lobal on the other hand, there may be a substantial deformation of this configuration with regard to fibers at or near the surface. This observed smearing effect and the distortion of the cross-sectional dimension of the individual fibers at or near the surface of the textile material may contribute to the beneficial surface characteristics of the textile material product of the invention.
- FIG. 1 is a preferred apparatus of the invention designed to carry out the process of the present invention, and the apparatus of the invention may be fully understood by reference to the detailed description of the apparatus.
- FIGS. 2 through 5 are schematic views of alternative embodiments of the present invention, showing various means of obtaining intermittent mechanical impact between a sanding means and the fabric being finished.
- the fabric 10 to be treated is unrolled from a fabric supply roll 1 under controlled tension and led to guide rolls 2 and 3.
- Guide rolls 2 and 3 may either be fixed or idling rolls, and they function to position the direction of the fabric so that its continued path will be in approximately the vertical direction while it maintains contact over substantially its entire width with the lower guide plate 4a.
- the path of the fabric continues over the upper guide plate 4b of the guide plate set and passes between fabric stabilizing rods 5a and 5b over fabric guide plate set 6a and 6b and to guide rolls 7 and 8 which function to change the direction of the fabric, which then moves to fabric take-up roll 9 onto which it is wound.
- Guide plate sets 4a and 4b and 6a and 6b may be adjusted in both the horizontal and vertical directions.
- the construction of guide plate sets 4a, 4b, 6a and 6b may vary widely and may consist of plates as illustrated or actual channels.
- the fabric passes between abrasive rolls 11 and 11a and corresponding flap rolls 12 and 12a.
- the abrasive rolls are covered with a suitable abrasive material such as sandpaper, the grit size of which may vary depending upon the desired effect as described more fully below.
- Guideplates 4a and 4b and 6a and 6b are adjusted to position the fabric accurately so that it will pass near to but not touch sanding rolls 11 and 11a unless it is impacted onto the sanding rolls by action of flap rolls 12 and 12a as described more fully below.
- Attached by suitable means to rolls 12 and 12a are flaps illustrated in FIG. 1 as 13a, 13b, 13c and 13d on roll 12 and flaps 13e, 13f, 13g and 13h on roll 12a.
- the flaps may be installed as illustrated by simply bolting them onto the flap roll so that when the rolls are at rest the plane of the flaps is essentialy tangential to the rolls.
- the centrifugal force when the flap rolls are rapidly rotated, the centrifugal force will extend them substantially radially from the roll.
- the flaps may also be installed so that they extend radially from the flap roll even while the roll is at rest, i.e., in the absence of centrifugal forces.
- the flaps may be made of a wide variety of suitable reinforced or non-reinforced materials such as neoprene rubber, urethane, polyvinyl chloride, nylon, or even steel and other sheet materials and even composites thereof of sufficient durability and flexibility to accomplish the desired result.
- the flap rolls may be driven by motor 14 via drive shaft 24, pulleys 15 and 15a and 17 and 17a, belts 16 and 16a and shafts 18 and 18a.
- Sanding rolls 11 and 11a may be driven by motor 19 via drive shaft 25, pulleys 20 and 20a and 22 and 22a, belts 21 and 21a via shafts 23 and 23a.
- flap rolls 11 and 11a When in operation sanding rolls 11 and 11a rotate as do flap rolls 12 and 12a. The distance between flap rolls 12 and 12a and sanding rolls 11 and 11a respectively is adjusted so that in the absence of fabric 10 the flaps would impinge upon sanding rolls 11 and 11a to a predetermined depth of the flaps. When the machine is operating and threaded up with fabric 10, flaps 13a-h will be extended substantially radially by centrifugal force from the rapidly rotating rolls 12 and 12a respectively and will intermittently impact the fabric with considerable force onto the sanding rolls 11 and 11a.
- the sanding rolls 11 and 11a and the flap rolls 12 and 12a may independently be rotated either clockwise or counterclockwise. Speed of rotation of both the sanding rolls and flap rolls may also vary widely depending upon the desired effects as described below.
- FIG. 2 provides a more detailed representation of a treatment station which comprises the sanding roll 11 and flap roll 12 with flaps 13a, 13b, 13c and 13d and fabric guideplates 4a and 4b.
- the fabric 10 is shown while being impacted by flap 13c onto the abrasive cover of the sanding roll 11.
- FIG. 1 illustrates only two treatment stations both of which are of the same type as that illustrated in FIG. 2, the actual apparatus may include only one station or alternatively two or more stations, e.g., three, four or even more stations may be provided on the apparatus for treatment of one or both sides of the fabric.
- the treatment stations furthermore, need not necessarily be all of the same type as illustrated in FIG. 1 but rather may include stations of different types, e.g., those illustrated in FIGS. 3 and 4 discussed below, as well, even on the same apparatus.
- FIGS. 3, 4 and 5 illustrate alternative treatment stations provided with means by which the fabric may be caused to impact onto a rapidly moving abrasive means, although it should be appreciated that there may be others within the scope of the present invention.
- the fabric 10 is caused to impact onto the abrasive covered roll 11 by means of a rapidly rotating non-circular bar, for instance as illustrated a square bar 30 which will alternately allow the fabric to clear the sanding roll and to impact it upon the roll.
- the roll 11 may be covered with a compressible foam which is placed on the roll between its outer periphery and the abrasive means so that the impact of the fabric 10 upon the abrasive means is softened and jamming of the fabric between the abrasive means and the impacting means is prevented.
- the non-circular bar 30 may be covered with a compressible foam for the same purpose.
- the impacting means 30 be disposed either above or below the point of closest proximity between the abrasive means 11 and the impacting means.
- Such disposition of the impacting means may also be advantageous in the alternative embodiment illustrated, for instance, in FIGS. 2, 4 and 5 as well as in other embodiments where the impacting means may be, for instance, an oscillating bar or even a rotating eccentric roll, and the like.
- FIG. 4 illustrates a further embodiment where an intermittent airstream 40 is emitted from a nozzle 42 to cause the fabric 10 to be impacted intermittently upon the surface of the sanding roll 11.
- FIG. 5 illustrates yet another embodiment of the apparatus of the present invention.
- the fabric 10 is moved over idler roll 50 changing its direction and then over spacing rolls 51, 52, 53, 54 and 55. Then the fabric is caused to move over idler roll 56 to again change the fabric direction.
- the spacing rolls are designed to prevent contact between the fabric 10 and the sanding surface unless impacted upon it by the flaps as illustrated.
- flap rolls 62, 63, 64 and 65 impact the fabric 10 onto the abrasive-covered surface of 11b with flaps 66a through d, 67a through d, 68a through d and 69a through d.
- fabrics may benefit from being processed according to the present invention.
- fabrics include woven, knit, non-woven fabrics, as well as coated fabrics and the like.
- Even certain films may benefit from treatment according to the present invention and films made from polymers, paper, and even natural products in sheet form such as leather may be processed according to the present invention.
- knit fabrics include double knits, jerseys, tricots, warp knit fabrics, weft insertion fabrics, etc.
- Woven fabrics may be plain weaves, twills or other well-known constructions.
- Such fabrics may be constructed from spun or filament yarns or may be constructed by using both types of yarns in the same fabric.
- Fabrics made from natural fibers such as wool, silk, cotton, linen may also be treated, although the preferred fabrics are those made from synthetic fibers such as polyester fibers, nylon fibers, acrylic fibers, cellulosic fibers, acetate fibers, their mixtures with natural fibers and the like. Particularly significant improvement in the surface characteristics of fabrics has been observed on fabrics containing polyester fibers.
- fabrics processed according to the present invention generally may be characterized as having a more uniform surface finish than fabrics processed according to conventional methods.
- the process may be used to provide a finish on the fabric surface which may be apparent to the naked eye, or a finish may be achieved which may not be apparent to the naked eye but which is quite apparent to the touch.
- the fabric may assume a generally softer hand and the fabric bending modulus may be reduced.
- Fabric such as knit texturized polyester filament fabrics may be caused to shrink upon being processed according to the present invention in the width direction resulting in a higher fabric weight. Furthermore, even if the fabric is stretched again to its original width and approximately its original weight per unit area, the fabric may generally be characterized as having a fuller, bulkier hand. Polyester filament fabrics may lose their undesirable "plastic-like" feel and the hand of such fabrics will become more similar to fabrics made from natural fibers such as wool or cotton. Products such as polyester double knit fabrics may, in certain instances, be characterized as having a density, uniformity and shortness of cover which cannot be obtained practically by means of conventional sanding or napping techniques.
- the process of the present invention permits finishing of fabrics which are generally too stretchy or too light in weight to be finished by conventional sanding techniques.
- Conventional methods rely frequently on tension to bring the fabric into contact with the sanding means. Where contact is accomplished by compressing the fabric between a backing and the sanding surface, tension is required to keep the fabric from being grabbed by the sanding roll and wrapped around it. Due to the intermittent nature of the contact with the sanding roll and due to the proper use of fabric guiding plates a considerably lower amount of tension is sufficient according to the process of the present invention so that it is possible to finish very lightweight fabric such as lightweight jersey knits.
- the process of the present invention is not limited, however, to textile materials per se and, for instance, application of the process to clear films may result in a matte-type finish providing a translucent film.
- Application of the process to paper of sufficient strength to undergo treatment may result in a softening of the surface of the paper.
- successive adjacent sections of the fabric are intermittently impacted upon an abrasive means across the entire width of the fabric.
- the fabric is ordinarily extended to its open width and may be moved in the warp or longitudinal direction. Sustained substantial contact between the fabric and the abrasive means is avoided, the mechanical impact being of a force and frequency sufficient to cause a substantially uniform modification of the surface characteristics of the fabric.
- the extent of modification of the surface characteristics, the specific effects obtained, and the rate at which these effects may be obtained will depend upon the operating conditions of the machine used in the process and the nature of the fabric being treated.
- Operating parameters of the apparatus used in the process e.g., force and frequency of impact, grit size of abrasive means and other variables, may be adjusted over a broad range.
- the linear speed of the fabric relative to the sanding means may vary from about 1 yard to about 200 yards per minute and will preferably be between about 5 and about 100 yards per minute, depending upon the number of treatment stations available, the type of fabric and intensity and character of the treatment desired.
- the grit of the sanding paper may vary widely, with grit sizes of about 16 to about 600, preferably between about 80 and about 400, e.g., about 180 to about 320 being appropriate.
- different size grits may be employed for the different sanding rolls in different sequences to accomplish specific effects. For example, it has been found desirable to pretreat the fabric at a first sanding station with a fairly coarse grit in order to make the fabric surface more easily alterable by the subsequent finer grits at subsequent treatment stations.
- the use of finer grit sanding paper will be particularly recommended for lighweight fabrics made from fine denier fibers or filaments, and will also be recommended for other fabrics, if a particularly subtle and fine finish is desired and when it is desired that the effects of the treatment be confined primarily to the fabric surface.
- the relative intensity of the treatment accomplished by means of the present invention is dependent not only upon the grit of the abrasive means but also on the force of the impact of the fabric on the abrasive means. This is in turn a function of the radius of the flap roll, flap length, bending modulus of the flaps, specific gravity or density of the flaps and the extent to which the flap front edge does not clear the surface of the opposing sanding roll and speed of rotation of the flap roll.
- the surface speed of the sanding means relative to the fabric may vary widely and may be between about 10 feet per minute and about 8,000 feet per minute, preferably between about 500 feet per minute and 2,500 feet per minute.
- the sanding roll may be rotated clockwise or counterclockwise and the direction of rotation of the flap rolls may either correspond to that of the sanding roll or may be opposite thereto. For instance, where the sanding roll and the flap rolls are both rotated in a clockwise direction very lightweight, stretchy fabric may have less tendency to be grabbed by the sanding roll and to wrap around it.
- the force at which the fabric is caused to impact upon the abrasive means is a function of the speed of rotation of the flap roll, the length and stiffness of the flaps, the diameter of the flap roll, as well as the density of the flap material, and other variables, but generally the flap roll will rotate at speeds from about 100 to about 8,000 rpm's, preferably from about 500 to about 6,000, e.g., about 1,000 to about 4,000 rpm's.
- Fabrics which have been processed pursuant to the present invention may be subjected to various subsequent treatment operations. It has been found, for instance, that a particularly appropriate post treatment for the products of the present invention may be brushing.
- fabrics may be mechanically surface finished according to the invention using comparatively mild treatment conditions, e.g., a relatively fine grit sandpaper as the abrasive means, or a relatively low impact force of the fabric onto the abrasive means, or a comparatively lower frequency of impact so that the strength of the fabric is reduced less than it might otherwise be.
- comparatively mild treatment conditions e.g., a relatively fine grit sandpaper as the abrasive means, or a relatively low impact force of the fabric onto the abrasive means, or a comparatively lower frequency of impact so that the strength of the fabric is reduced less than it might otherwise be.
- brushing the fabric vigorously using, for example, nylon or metal brushes, such as brass or steel brushes modification of the surface characteristics of the fabric may be desir
- a doubleknit fabric was prepared from 1/150/50 Monsanto type 446 100 percent texturized polyester filament yarn.
- the fabric was scoured, jet-dyed to a light blue color, slit and then heat set to provide a control sample.
- the finished weight was between 133/4 and 141/4 ounces per yard, with a width of between 60 and 62 inches.
- the Mullen Burst Strength (ASTM No. D-231 (1975)) was 275 lbs.
- FIGS. 6 and 7 are scanning electron photomicrographs (SEPM) taken of the fabric at 100X and 350X respectively.
- a separate sample of the above yarn was knitted and the resulting doubleknit was then processed by scouring, jet-dyeing to a light blue color and slitting. After slitting, but prior to heat setting the fabric was mechanically surface treated according to the process of the present invention to provide a product of the present invention. SEPMs of the sample are provided in FIGS. 8 and 9 at 100X and 350X. The processing parameters are set forth below in the Table. After treatment, the Mullen Burst value was 235 lbs.
- Another sample of the above fabric was treated in substantially the same manner as set forth above for the sample according to the invention, although it was colored navy blue and instead of mechanically surface finishing prior to heat setting according to the present invention it was Gessner sanded.
- the Mullen Burst value for the Gessner-sanded product after treatment was 230 lbs.
- SEPMs of the Gessner-sanded product are set forth below in FIGS. 10 and 11 at 100X and 350X.
- the fabric treated according to the present invention revealed that it had a very luxurious, warm and soft surface hand and a very short, dense cover. The cover was readily apparent to the naked eye although because of its relative shortness it permitted the construction of the fabric to be fully visible.
- the control fabric that is the fabric that has had no mechanical surface finishing, by contrast had a clear surface, no cover, and had the typical hard, "plastic", somewhat slick appearance and hand of texturized polyester doubleknits.
- the appearance and hand of the sample treated according to the present invention was comparable to that of a fabric prepared from fine wool yarns.
- the sample which was conventionally surface finished by means of a Gessner sander did not approach the desirable characteristics of the sample treated according to the present invention, especially with regard to softness of hand, density of cover, and similarity to a fabric made of fine wool yarns.
- Reference to the SEPM of the control sample, the sample treated according to the present invention, and the conventionally sanded sample at magnifications of 100X and 350X shows that the fibers of the fabric of the present invention are broken to some extent but are predominately extensively modified by the formation of lamella shaped protrusions on the fiber surfaces and by the formation of scar type surface modifications on the fiber surfaces.
- the Gessner-sanded samples by contrast show a substantial number of cut and broken fibers with only very minor modification of the surface characteristics of the individual fibers.
- Example 1 was repeated using a 1/150/34 100 percent texturized polyester filament yarn.
- a control (untreated) sample, Gessner-sanded sample and a sample treated according to the invention were prepared.
- the Gessner-sanded sample exhibited no significant difference from the untreated control sample, and the product in fact did not have a commercially acceptable finish due to the relatively coarse nature of the 150/34 texturized polyester yarns from which it was made.
- This same fabric which was treated according to the present invention had a significantly improved surface feel and a warm, pleasant wool-like hand as compared to the control sample.
- the sample compares very favorably to the Gessner-sanded version made according to Example 1 from the more expensive 150/50 texturized polyester filament yarns.
- the Mullen Burst value for the untreated control was 285 lbs. as compared to 220 lbs. after Gessner-sanding and 240 lbs. after surface finishing according to the present invention.
- the surface modification is significant according to the process of the present invention, less strength loss is observed compared to Gessner-sanding.
- the fabric used in this Example was a yarn-dyed, polyester doubleknit.
- the yarn used was a 1/150/34 texturized 100 percent polyester filament yarn.
- the control sample was prepared by sponging, slitting and drycleaning the knitted fabric.
- the finished weight was 12.4 ounces per yard, with a width of 64 inches, and a Mullen Burst strength of 215 lbs.
- the sample of the present invention was then processed as set forth in the Table.
- the Mullen Burst value was 120 lbs. After surface finishing the fabric was heat set, sheared, heat set again and decated.
- the finished weight was 11.6 ounces per yard, with a width of 60 inches.
- a sample of the same cloth was then processed in the same manner as described above except that instead of mechanical surface treating according to the present invention the fabric was napped after the first heat setting operation, and then sheared, heat set again and decated.
- the finished weight was 11.70 ounces per yard with a width of 591/4 inches.
- the fabric treated according to the process of the invention had a very soft, cotton-like surface hand as compared to the typical hard, slick, "plastic" and unappealing hand of the untreated control sample. Because of the relative shortness of the cover on the fabric treated according to the invention the clarity of the pattern of the fabric was not obscured to any measurable extent except for a very minor reduction of color contrast. The fabric construction, however, was still discernable.
- the napped fabric made from the same control fabric had a much harsher, drier somewhat woll-like hand. Both the color pattern on the surface and the construction features of the fabric were extensively obscured by napping.
- FIGS. 12, 13 and 14 are SEPMs at 35X, 100X and 350X of the control sample.
- FIGS. 18, 19 and 20 show SEPMs at 35, X 100X and 350X respectively of the napped samples. Comparison of the SEPMs reveals that the fibers at or near the surface of the sample which has been treated according to the process of the invention are relatively severely modified with the formation of lamella-type protrusions and scars as well as by a very small amount of cut fibers. The napped samples by contrast show very little or no actual fiber surface modification although there are a substantial number of cut fibers.
- the characteristics obtainable by the process of the invention applied to 100 percent polyester woven fabrics made from a filament warp yarn and a spun filling yarn were compared.
- the starting fabric was woven from a 2/150/34 Danbury-242T Dacron polyester filament warp yarn (lot number 841).
- the filling yarn was a spun 12/1 T-350 Trevira polyester yarn.
- the control sample was prepared by Mezzera treatment, jet-dyeing with a navy blue dye, and finished by heat setting, shearing, and decating.
- the finished width was 59.4 inches (inside selvedges) with a weight of 11.5 ounces per yard.
- the strength as measured by the Scott Grab Tensile test (ASTM number D-1682, (1975)) was 263 lbs. for the warp and 156 lbs. for the fill.
- the above processing sequence for the control sample was modified by surface treatment according to the present invention prior to Mezzera treatment with the remaining steps in the process being identical to those set forth above for the control sample.
- the finished weight and width were the same as for the control sample.
- the mechanical surface treatment conditions are set forth in the Table below. After treatment the Scott Grab Tensile (SGT) value was for the warp 205 lbs. and for the fill 47 lbs.
- the samples treated according to the invention generally had a very attractive, soft and pleasant wool or cotton-like hand, while the fabric which did not have any surface treatment had the customary hard, harsh feel of polyester fabric.
- the sample which was napped resulted in a relatively soft surface hand as compared to conventional sanding, but it did not produce either a pleasant or a soft surface finish as was achieved according to the present invention, especially where the surface treatment was performed prior to dyeing.
- FIGS. 25 and 26 are SEPMs of the control samples at 100X and 350X respectively.
- FIGS. 27 and 28 are the Gessner-sanded samples at 100X and 350X
- FIGS. 29 and 30 are the samples which were napped, again depicted at 100X and 350X.
- FIGS. 31 and 32 are the samples which were finished according to the present invention by mechanical surface treatment after dyeing but prior to shearing and decating. Examination of SEPMs of the samples mechanically surface finished prior to Mezzera treatment and those treated after Mezzera treatment but prior to dyeing appeared almost identical to FIGS. 31 and 32 and, therefore, need not be shown.
- the fabric samples treated according to the invention whether prior to dyeing or after dyeing, all showed substantial lamella protrusions from the surface of the fabric as well as a substantial amount of scarring. Plastic deformation of the fibers was also evident. Conventional Gessner sanding resulted by contrast in only a limited amount of fiber surface modification with little or no lamella formation and no plastic deformation of the fibers. Napping resulted in even less fiber surface modification, no plastic deformation of the polymeric fibers although a significant amount of fiber cutting is apparent.
- a jersey knit was mechanically surface finished according to the present invention and compared with a non-finished control sample.
- the control was prepared from 100 percent Dacron polyester T-56 1/70/34 yarns.
- the sample was processed by Mezzera treatment, jet-dyeing a light green color, slitting and heat setting.
- the finished weight was 5.75 ounces per yard with a width of 63 inches.
- the Mullen Burst strength was 130 lbs.
- sample treated according to the present invention had a soft, warm, and luxurious hand; while the untreated control had a relatively slick surface hand typical of polyester fabrics.
- the sample treated according to the invention may be said to have a hand that is comparable to that of fabrics made from spun yarns.
- Samples of 65/35 polyester cotton blends were treated according to the present invention and then compared to control samples.
- the warp and fill yarns were both 65 percent polyester, 35 percent cotton.
- the control sample was prepared by singeing and mercerizing the fabric.
- the finished weight was 4.86 ounces per square yard and the finished width was 60.3 inches.
- a separate sample of the fabric was processed in the same manner as the control sample but was subsequently finished by treating according to the process of the invention.
- the treating conditions are set forth in the Table. For comparison purposes another sample was treated as above by singeing, mercerizing and then Gessner sanding, followed by range dyeing, finished and sanforizing of the cloth.
- FIGS. 33 and 34 are SEPMs of the control sample at 100X and 350X.
- FIGS. 35 and 36 are SEPMs of the sample which was processed according to the invention, also at 100X and 350X.
- FIGS. 37 and 38 are SEPMs at 100X and 350X of the Gessner-sanded sample. Examination of the SEPMs revealed that the sample which was treated according to the process of the invention has lamella-type protrusions on the fibers at or near the surface of the fabric. There were also a few cut fibers, scarring and significant thermoplastic deformation of the polyester fibers. It was also evident that the yarns immediately at the surface of the fabric were flattened, apparently in conjunction with thermoplastic deformation of the polyester fibers. Observation of the SEPMs of the Gessner sanded samples revealed that the process resulted in very little modification of the surface fibers although certain randomly oriented fibers and some cut fibers were present on the fabric surface.
- a sample of woven 80/20 polyester cotton having a spun warp and a filament fill yarn was treated according to the process of the invention and compared with a control sample.
- the warp yarn was a 65 percent polyester, 35 percent cotton yarn.
- the fill yarn was a texturized 100 percent polyester filament yarn.
- the control sample was prepared by the steps of heat setting, singeing and mercerizing.
- the finished weight was 4.94 ounces per square yard and the finished width was 60.2 inches.
- SGT strength of the warp was 133 lbs. and 131 lbs. for the fill.
- a sample of the above fabric processed in the identical manner was finished by mechanical surface treatment according to the process of the invention.
- the finished weight and width were both the same as for the control sample.
- the processing conditions are set forth in the attached Table.
- the resulting SGT strength was 122 lbs. for the warp and 101 lbs. for the fill.
- a similar fabric having a spun warp yarn of 65 percent polyester and 35 percent cotton and a fill yarn of texturized 100 percent polyester filament yarn was processed by heat setting, steam treating, mercerizing, and range dyeing to provide a tan fabric.
- the fabric was then conventionally Gessner sanded, finished and sanforized.
- the finished weight was 5.35 ounces per square yard, and the finished width was 60.5 inches.
- the SGT strength for the warp was 207 lbs. and for the fill was 181 lbs. The tensile strength characteristics of the fabric prior to treatment were unavailable.
- FIGS. 39 and 40 are SEPMs of the control sample at 100X and 350X.
- FIGS. 41 and 42 are SEPMs taken at 100X and 350X of a sample which has been prepared in the same manner as the control sample and then mechanically surface finished according to the invention.
- FIGS. 43 and 44 are SEPMs of the sample which has been Gessner sanded and prepared as described above. Examination of the SEPMs shows that very few of the fibers are cut in the sample processed according to the present invention. Rather, the surface of the fibers has been significantly modified in the process. Some lamella-type protrusions are produced and scarring was particularly obvious. Some plastic deformation of the polyester fibers was observed. Also, a flattening of the yarn surfaces was again observed. With regard to the Gessner-sanded sample, except for some cutting of the fibers there was little apparent effect on the fibers of the fabric.
- a 100 percent filament embossed woven polyester napery fabric was treated according to the process of the invention, and its characteristics were compared to that of an untreated control sample.
- the sample treated according to the invention had a pleasing appearance resembling that of genuine cotton jacquard damask fabric and even the depressed embossed areas of the fabric were beneficially affected.
- the untreated control sample had a glass-like sheen and a plastic appearance quite dissimilar to the subtle and fine appearance of the high priced jacquard woven damask fabric.
- a control sample of woven 100 percent polyester filament warp and fill napery fabric was prepared and its characteristics were compared to that of a similar sample which was treated according to the process of the invention. It was observed that in addition to the improved surface hand characteristics, tablecloths or napkins made from the above-described material and processed according to the invention could be stacked without the piles of stacked fabric sliding and falling down. The overall appearance of the fabric was, however, changed very little and the fabric had a completely clear face. However, the fabric in effect did have a very advantageous cotton-like hand.
- This Example illustrates application of the process of the invention to a 100 percent nylon nonwoven point-bonded fabric.
- a control sample was prepared and a separate sample was subsequently processed according to the invention.
- the processing conditions are set forth in the Table.
- the nonwoven nylon fabric when treated according to the process of the invention exhibited a dramatically softer, kinder surface hand than the slick, "glassy" starting material.
- a dense, somewhat longer cover was created giving the surface of the fabric the touch and surface feel of material made from the natural fibers. Little strength loss was encountered due to the treatment of the fabric.
- Comparison of the SEPMs of the sample treated according to the process of the invention shown in FIGS. 45 and 46 at 100X and 350X respectively to the control samples as shown in FIGS. 47 and 48 at 100X and 350X respectively shows that there has been a significant generation of lamella-type protrusions on the fiber surface, fiber surface scarring, and visual observation revealed cut fibers.
- a control fabric was prepared of a napped substrate fabric containing on its surface a coagulation type coating.
- a separate sample of the fabric was processed according to the invention using the processing conditions set forth in the Table.
- a heavy duty paper (white, light cardboard-type) was subjected to mechanical surface treatment according to the present invention.
- the paper had a thickness of 11 to 12 mils. Observation of the product after treatment revealed that mechanical surface treatment of the paper resulted in a mat, non-slick surface as compared to the untreated control sample.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Treatment Of Fiber Materials (AREA)
Priority Applications (30)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US06/092,815 US4316928A (en) | 1979-11-09 | 1979-11-09 | Mechanically surface finished textile material |
CA000362586A CA1153192A (en) | 1979-11-09 | 1980-10-16 | Mechanical surface finishing apparatus, process and product |
PT7197580A PT71975B (en) | 1979-11-09 | 1980-10-27 | Apparatus and mechanical procedure for superficial finishing and products obtained thereof |
GB8034630A GB2063322B (en) | 1979-11-09 | 1980-10-28 | Surface abrasion treatment |
AU63815/80A AU519798B2 (en) | 1979-11-09 | 1980-10-29 | Surface finishing apparatus, processes and products |
NZ19542280A NZ195422A (en) | 1979-11-09 | 1980-10-31 | Modification of surface of sheet material by surface abrasion |
NL8006032A NL180030C (nl) | 1979-11-09 | 1980-11-04 | Werkwijze en inrichting voor het mechanisch afwerken van een oppervlak van een textielmateriaal. |
SE8007779A SE451022B (sv) | 1979-11-09 | 1980-11-05 | Forfarande och anordning for mekanisk ytbehandling av textilvaror |
MX184635A MX155380A (es) | 1979-11-09 | 1980-11-06 | Procedimiento y aparato mejorados para el acabado superficial mecanico de una tela textil |
DE3041966A DE3041966C2 (de) | 1979-11-09 | 1980-11-06 | Textilmaterial aus wenigstens teilweise synthetischen Fasern mit seitlich abstehenden Vorsprüngen, sowie Verfahren und Vorrichtung zum mechanischen Oberflächenveredeln eines Textilmaterials |
JP55156752A JPS5943581B2 (ja) | 1979-11-09 | 1980-11-07 | 織物繊維の機械的表面処理法 |
LU82918A LU82918A1 (fr) | 1979-11-09 | 1980-11-07 | Procede et appareil de traitement mecanique de finition d'etoffes,et matiere textile obtenue par leur mise en oeuvre |
DK475580A DK157496C (da) | 1979-11-09 | 1980-11-07 | Fremgangsmaade og apparat til mekanisk overfladebehandling af et materialelag og et hermed fremstillet tekstilmateriale |
AT548680A AT371154B (de) | 1979-11-09 | 1980-11-07 | Textilmaterial sowie verfahren zu dessen herstellung und vorrichtung zur durchfuehrung des verfahrens |
IE2318/80A IE50911B1 (en) | 1979-11-09 | 1980-11-07 | Mechanical surface finishing apparatus,process and product |
CH8295/80A CH647284A5 (fr) | 1979-11-09 | 1980-11-07 | Procede et machine de traitement mecanique de surface d'une etoffe et etoffe produite. |
FR8023930A FR2469489B1 (fr) | 1979-11-09 | 1980-11-07 | Procede et appareil de traitement mecanique de finition d'etoffes, et matiere textile obtenue par leur mise en oeuvre |
BE0/202730A BE886075A (fr) | 1979-11-09 | 1980-11-07 | Procede et appareil de traitement mecanique de finition d'etoffes, et matiere textile obtenue par leur mise en oeuvre |
IE41480A IE50912B1 (en) | 1979-11-09 | 1980-11-07 | Surface-abraded textile fabrics |
ES496641A ES8202883A1 (es) | 1979-11-09 | 1980-11-07 | Un procedimiento para dar un acabado superficial mecanico o una tela textil y aparato correspondiente. |
IT5010680A IT1147021B (it) | 1979-11-09 | 1980-11-07 | Procedimento ed apparecchio per la finitura superficiale di tessuti e prodotto ottenuto |
KR1019800004297A KR840001027B1 (ko) | 1979-11-09 | 1980-11-08 | 기계적 표면 가공방법 |
FR8111949A FR2483476A1 (fr) | 1979-11-09 | 1981-06-17 | Matiere textile obtenue par un traitement mecanique de finition |
US06/282,446 US4468844A (en) | 1979-11-09 | 1981-07-13 | Mechanical surface finishing process for textile fabric |
ES1981261771U ES261771Y (es) | 1979-11-09 | 1981-11-30 | Un articulo textil. |
CA000416528A CA1156028A (en) | 1979-11-09 | 1982-11-26 | Mechanical surface finishing apparatus, process and product |
GB08312571A GB2127868B (en) | 1979-11-09 | 1983-05-06 | Surface-abraded textile fabrics |
US06/604,771 US4512065A (en) | 1979-11-09 | 1984-04-27 | Mechanical surface finishing apparatus for textile fabric |
HK80084A HK80084A (en) | 1979-11-09 | 1984-10-18 | Surface abrasion treatment |
HK30985A HK30985A (en) | 1979-11-09 | 1985-04-18 | Surface-abraded textile fabrics |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US06/092,815 US4316928A (en) | 1979-11-09 | 1979-11-09 | Mechanically surface finished textile material |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US06/282,446 Continuation-In-Part US4468844A (en) | 1979-11-09 | 1981-07-13 | Mechanical surface finishing process for textile fabric |
Publications (1)
Publication Number | Publication Date |
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US4316928A true US4316928A (en) | 1982-02-23 |
Family
ID=22235270
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US06/092,815 Expired - Lifetime US4316928A (en) | 1979-11-09 | 1979-11-09 | Mechanically surface finished textile material |
Country Status (22)
Country | Link |
---|---|
US (1) | US4316928A (xx) |
JP (1) | JPS5943581B2 (xx) |
KR (1) | KR840001027B1 (xx) |
AT (1) | AT371154B (xx) |
AU (1) | AU519798B2 (xx) |
BE (1) | BE886075A (xx) |
CA (1) | CA1153192A (xx) |
CH (1) | CH647284A5 (xx) |
DE (1) | DE3041966C2 (xx) |
DK (1) | DK157496C (xx) |
ES (2) | ES8202883A1 (xx) |
FR (2) | FR2469489B1 (xx) |
GB (1) | GB2063322B (xx) |
HK (2) | HK80084A (xx) |
IE (1) | IE50911B1 (xx) |
IT (1) | IT1147021B (xx) |
LU (1) | LU82918A1 (xx) |
MX (1) | MX155380A (xx) |
NL (1) | NL180030C (xx) |
NZ (1) | NZ195422A (xx) |
PT (1) | PT71975B (xx) |
SE (1) | SE451022B (xx) |
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US4468844A (en) * | 1979-11-09 | 1984-09-04 | Milliken Research Corporation | Mechanical surface finishing process for textile fabric |
US4512065A (en) * | 1979-11-09 | 1985-04-23 | Milliken Research Corporation | Mechanical surface finishing apparatus for textile fabric |
US5126191A (en) * | 1989-12-22 | 1992-06-30 | Establissements Les D'auguste Chomarat Et Cie | Process for the production of a textile reinforcing web for composite materials based on resins and new type of web |
WO1993023222A1 (en) * | 1992-05-12 | 1993-11-25 | Wetmore Associates | Ultraviolet protective fabric |
US5416958A (en) * | 1992-01-21 | 1995-05-23 | Basf Corporation | Easy nap textile fabric and process for making |
US20030033698A1 (en) * | 2001-08-17 | 2003-02-20 | Tietex International, Ltd | Fabric having a decorative textured surface |
US6605332B2 (en) * | 1997-07-29 | 2003-08-12 | 3M Innovative Properties Company | Unitary polymer substrate having napped surface of frayed end microfibers |
US20040098809A1 (en) * | 2002-11-26 | 2004-05-27 | Love Franklin S. | Process for face finishing fabrics and fabrics having good strength and aesthetic characteristics |
US20050136777A1 (en) * | 2003-12-23 | 2005-06-23 | Kimberly-Clark Worldwide, Inc. | Abraded nonwoven composite fabrics |
US20050186873A1 (en) * | 2004-02-24 | 2005-08-25 | Milliken & Company | Treated textile substrate and method for making a textile substrate |
US20050186872A1 (en) * | 2004-02-24 | 2005-08-25 | Milliken & Company | Treated textile substrate and method for making a textile substrate |
US20070044286A1 (en) * | 2005-09-01 | 2007-03-01 | Shigeru Nohara | Method of manufacturing fleece having different kinds of fibers in front and back faces |
US20080052884A1 (en) * | 2006-08-29 | 2008-03-06 | Northeast Textiles, Inc. | Method of producing a twill weave fabric with a satin face |
US20150259843A1 (en) * | 2014-03-11 | 2015-09-17 | Welspun India Limited | Natural finish fabric |
ITUB20152274A1 (it) * | 2015-07-17 | 2017-01-17 | Ribbontex Srl Uninominale | Processo di produzione di un nastro e nastro cosi' ottenuto |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
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FR2628762A1 (fr) * | 1988-03-18 | 1989-09-22 | Saligny Claude | Procede d'obtention de motifs suivant un dessin predetermine a la surface d'articles textiles ou materiaux similaires et installation pour sa mise en oeuvre |
US5058329A (en) * | 1990-01-08 | 1991-10-22 | Milliken Research Corporation | Machine and method to enhance fabric |
US5109630A (en) * | 1990-01-08 | 1992-05-05 | Milliken Research Corporation | Machine and method to enhance fabric |
DE4135855A1 (de) * | 1991-10-31 | 1993-05-06 | Gebrueder Sucker + Franz Mueller Gmbh & Co, 4050 Moenchengladbach, De | Tambour-schmirgelmaschine |
US5392499A (en) * | 1993-04-15 | 1995-02-28 | Sperotto Rimar S.P.A. | Method and apparatus for surface treatment of wet fabric webs in a finishing machine |
JP2914166B2 (ja) * | 1994-03-16 | 1999-06-28 | 日本電気株式会社 | 研磨布の表面処理方法および研磨装置 |
DE29812472U1 (de) | 1998-07-15 | 1998-11-05 | Gebrüder Munzert GmbH & Co., 95119 Naila | Flachgewebe mit velourartiger Oberfläche |
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